TUNNEL BORING MACHINES IN DIFFICULT GROUNDS …sahin/tuneller/1.BOLUM_EK_2017_TBM-Digs-Avrasya... · TBM MANUFACTURER Herrenknecht AG CONSTRUCTION COMPANY (EPC JV) YMSK Joint Venture

1

A UNIQUE PROJECT UNDER VARIABLEGEOLOGICAL AND WORKING CONDITIONS: EURASIA TUNNEL

16 November 2016Steigenberger Hotel, Maslak - Istanbul, Turkey

Dr. Eng. Burak GÖKÇEYapı Merkezi

Prof. Dr. Eng. Ergin ARIOĞLUYapı Merkezi

Dipl. Eng. Başar ARIOĞLUYapı Merkezi

TUNNEL BORING MACHINES IN DIFFICULT GROUNDSTURKISH TUNNELLING SOCIETY

2

CAUTION

This presentation is prepared by:

Prof. Dr. Eng. Ergin ARIOĞLU - Yapı Merkezi R&D Department

Dipl. Eng. Başar ARIOĞLU - Yapı Merkezi İnşaat A.Ş.

Dr. Eng. H. Burak GÖKÇE - Yapı Merkezi R&D Department

In this report the remarks, evaluations made and conclusion drawn, that are under

progress, do not reflect the opinions of Yapı Merkezi Construction and Industry Inc. No

liability for negligence or otherwise can be accepted by Yapı Merkezi.

© 2016 Yapı Merkezi Construction and Industry Inc. All Rights Reserved. Except as

otherwise permitted by Yapı Merkezi Construction and Industry Inc., this publication, or

parts thereof, may not be reproduced in any form, by any method, for any purpose.

http://www.ym.com.tr/

3

Trakya Formation

Marmara Sea

CONTENT

Source: ATAŞ (2014)

Project in Brief

Seismicity

Geology

Geotechnics

Tunnel Boring Machine

Advance Rates

Standstills

Excavation Parameters

Conclusions

Acknowledgements

4

PROJECT IN BRIEF

Model: Build – Operate – TransferTotal Investment: ~1,3 Billion $Construction Period: 55 Months

• Road and tunnel structuresOperation Period: ~ 26 Years

Total Project Length: 14.6 km

•Part-1: Europe side (5,4 km)

•Part-2: Bosphorus Crossing (5,4 km)

•Part-3: Asia side (3,8 km)

1st and 2nd bridges (total 7x2 lanes)• 180.000 (1st) and 220.000 (2nd) crossings

per dayEurasia Tunnel (2x2 lanes)• 110.000 crossings per day (both directions)

5

GUARANTOR Republic of Turkey Prime MinistryUndersecretariat of Treasury

SPECIAL PURPOSE COMPANY Eurasia Tunnel Operation Const. & Invest. Inc.

OPERATOR EGIS Tunnel Operation Co.

TBM MANUFACTURER Herrenknecht AG

CONSTRUCTION COMPANY (EPC JV)YMSK Joint Venture

OWNER

INVESTOR / CONTRACTOR

Ministry of Transportation

General Directorate of Infrastructure Investments

Yapı Merkezi Construction Inc.

SK Engineering & Construction Company Ltd.

DESIGNER

INDEPENDENT DESIGN VERIFIER HNTB Corporation

Parsons Brinckerhoff

REINSURANCE & INSURANCEMunich RE

Zurich RESEGMENT PRODUCER

Yapı Merkezi Prefabrication Inc.

ADVISORSSUBJECT

TRAFFIC

ENVIRONMENTAL & SOCIAL

INSURANCE

LEGAL

FINANCETAX

Jacobs Engineering Group

ERM Environmental Resources Mangt.

Marsh Insurance Ltd.

Hergüner Attorney Partnership

Skadden LLP

UniCredit GroupPricewaterhouseCoopers

Arup Group Ltd..

JLT Jardine Lloyd Thompson Group

Fidan & Fidan Law Firm

Clifford Chance LLP

PricewaterhouseCoopers

Arup Group Ltd.

SPONSORS’ ADVISORS LENDERS’ ADVISORS

PROJECT PARTIES

6

PROJECT CHRONOLOGY

Tender

City Plan Approval

TBM factory acceptance

Signing of IC

Ground-breaking Ceremony

Financial Close &

Commencing Construction

IC in effect & Asian Work Site Hand-over

Signing of Finance Agreements

STP Delivery to site accomplished

TBM at Site

Due Diligence Process Design & Construction

Initialing of IC

TBMLaunching

TBMBreakthrough

Pre & Detailed

FeasibilityStudy

ConstructionCompletion

Design

OperationCompletion

OperationTender

YM R&D YM R&D InternalInternal

Presentation


7

SUCCESSFUL SUBSEA TUNNELLING UNDER BOSPHORUS: MELEN PROJECT

Contractor: STFA + Mosmetrostoy ve Türk ALKE

Project Cost: ~120 milyon US$

Tunnel Length: 5,5 km

EPB-TBM Diameter: 6,15 m -operated in open mode-with "0" face pressure

Minimum Rock Cover Thickness: 35 m

Maximum Depth TBM Tunnel: 135 m (70m-sea)

Formasyon: Dolayoba/Kartal formation

Clayey limestone, limestone-shale, sandstone, GSI: 45-64 (subsea section), several dykes (andesite/diabase) with 1-70 m thickness

Started in March-2008 and finished in April-2009 (one month earlier than planned)

Source: Anagnostou (2010) and Bakır et al. (2011)

Avrupa Avrupa Yakası Anadolu Anadolu

Yakası

Ölçeksiz

Sarıyer Beykoz

SECTION EXCAVATED WITH A TBM (3,4 km) SECTION EXCAVATED BY DRILL&BLAST

Alüvyon

Deepest Point of TBM Tunnel Source: Modified from Gerek et al. (2010)

8

MAIN CHANGES OF EURASIA TUNNEL AFTER FIELD INVES.&PRELIMINARY STUDIES

Parameters Tender Documents Changes

Tunnel Diameter (m) 12.5 13.2

Tunnel Alignment Depth (m) -88.0 -106.4

Tunnel Gradient (%) 4.0 5.0

Face Support Pressure (bar) 9.0 11.0

Toll PlaceFor both traffic direction: European side

Asian-European direction:Asian side

European-Asian direction:European side

Geotechnical Parameters Based on Marmaray Project (there is a distance about 1.5 km)

Detailed desk/field and laboratoryinvestigations, structucture of seabottom markedly changes

Seismic Parameters General AssumptionsDetailed geophjysical studies andprobabilistic earthquakeapproaches

TBM Excavation Launch Method Deep shafts at European side Transition box at Asian side

Approaching Tunnels at Asian sideTunnel with variable-larger crosssections

Constant cross section

Eurasia tunnel Project with actual parameters is an unique Project in the World tunnel literature.


9

SEISMICALLY ACTIVE FAULT SEGMENTS IN THE MARMARA REGION

Fault segment EarthquakeS7, S8 10/9/1509 (Ms = 7.2)S9 10/5/1556 (Ms = 7.2)S2, S3, S4, S5 25/5/1719 (Ms = 7.4)S6 2/9/1754 (Ms = 6.8)S7, S8 22/5/1766 (Ms = 7.1)S11 5/8/1766 (Ms = 7.4)S3, S4, S5 10/7/1894 (Ms = 7.3)S11 9/8/1912 (Ms = 7.3)S1, S2, S3, S4 17/8/1999 (Ms = 7.8)

Fault Segment Last Earthquake Median Recurrence TimeS1 12/11/1999(Ms = 7.3) -S2 17/8/1999 (Ms = 7.8) 140 :± 35 years S3 17/8/1999 (Ms = 7.8) 140 :± 35 years S4 17/8/1999 (Ms = 7.8) 140 :± 35 years S5 10/7/1894 (Ms = 7.3) 175 yearsS6 2/9/1754 (Ms = 6.8) 210 :± 40 yearsS7 22/5/1766 (Ms = 7.1) 250 yearsS8 22/5/1766 (Ms = 7.1) 250 yearsS9 10/5/1556 (Ms = 7.2) 200 :± 50 years S10 - 200 :± 50 years S11 9/8/1912 (Ms = 7.3) 150 years

Major Earthquakes (Ms > 6) Median Recurrence Times of Fault Segments

Source: Erdik (2004) and Wang et al. (2005)

Eurasia Tunnel

North Anatolian Fault Zone

10

SEISMIC JOINTS

Shearr ±±±±±±±± 50 mm

Source: Modified from YMSK Joint Venture (2014)

Behaviorr off thee tunnelel underr ann earthquakeBehavwas

vior oof hethhavss designed

unntuheedd for

neunnrr a

l undeu rneeaa moment

nn earthquakeanatt magnitude

keakee ofwas

MMMMMw

s desdssw =

des== 7

siges7777777,

nensig77,25

edd forfedd55 and

aaa momemrr add design

entmenn of

magnitudemnttff functional

e ofodeell andMMww

safety7777,2225555 anda d777

yy evaluationdesignn ofof funcfddearthquakes

ctionalncss have

andaallee beensafetyy evae

analyzedaluation earevaaccording

rthqarto

uakessqreturn

haveh e beebhperiods

eneeofana

500lyzedlyz0000 and

ddd 222222.

cordiccac222222222222.500

ng ttrdi0000 years

totorrssss,

eturn periodr, respectively

dsriodlyly.

11

According to geological/geophysical studies (based on borehole logs and seismic refraction)

Asia Side Full face Trakya Formation with different joint, stiffness

and abrasiveness (sandstone, mudstone, dykes) ≈ 564 m

Asia Mixed face (weak and weathered rock mass and marine sediments) ≈ 112 m

Marine sediments (sandy / clayey soil) ≈ 752 m

Europe Mixed face ≈ 112 m

Europe Side Full face Trakya Formation ≈ 1800 m

TBM TUNNEL GEOLOGY OF EURASIA TUNNEL

Source: Yapı Merkezi Visual Design (2014)

LITOLOGY(Between Ring No: 0 - 1627)

Length (m)

Volcanic Dykes 413Fault & Crushed Zone 101

Source: Bakır, Aydın (2015)

12

Geological Strength Index (Cai et al. 2004)

Block Volume

Joint Condition Factor (Palmstrom, 1995)

ROCK MASS CHARACTERIZATION IN TRAKYA FORMATIONRange of Block Volume -gravel sized-

Wor

seni

ngJo

intC

ondi

tions

Block Volume becomes extremely small size

15

Expected GSI Values(shaded area)

Rock mass unit

Rock mass structure description

Joint/Block wall surface condition

GSIJoint sets

Joint spacingS (cm)

Block Volume, Vb

(cm3)Description

Joint condition factor, Jc

Typical blocky sandstone 3 30-100 2.7x104-106 Rough slightly weathered 1.7 – 4.5 55 - 75

Very blocky sandstone withmudstone/siltstone

3 or 4 10-30 103-2.7x104 Rough slightly weathered 1.7 – 4.5 45 - 65

Mudstone/siltstone with sandstone layers

4 10-30 103-2.7x104 Smooth, moderately weathered/altered surface

0.67 – 1.7 35 - 55

Tectonically disturbed, folded, faulted zones

> 4 3-10 27-1000Slickenslided variable weathered surfaces

0.25 – 0.67 20 - 35

Disintegrated completely crushed rock: translation

- < 3 <27Slickenslided highly weathered surface with clay coatings

0.1 – 0.25 < 20

Note: “Jw” stands for large-scale waviness and “Js”stands for small-scale smoothness. S1, S2, S3 arespacings between the individual joints in each setand γ1, γ 2, γ 3 are the angles between the joint sets.

13

VARIATION OF UNIAXIAL COMPRESSIVE STRENGTH WITH DEPTH

Source: Yapı Merkezi R&D (2010)

= mean values = standard deviationV = coefficient of variation (%),

V = s / x100

14

GENERAL OUTLOOK ON MARINE SEDIMENTS

Properties of marine sediments based on cone penetration test (CPT) and measured shear wavevelocity from P/S logging.

Marine sediments (Holecene aged, 7400 ± 1300) varies from coarse-grained soils (gravels and sand) to finegrained soils (silts and clays) and change both vertically and laterally as a result of sedimental regime.

The coarse-grained soils (usually silty/clayey fine sand) are dense. The sands own high stiffness under highconfining pressure.

Generally speaking, the marine sediments that are normally to lightly overconsolidated at the tunnel axisdepth and consist of inter-bedded sands, silts and clay. The soils appear to be normally consolidated i.e.OCR≈1, many design properties (undrained shear strength -cohesion value-, stiffness) enhance with depth.

Undrained shear strength can be approximated as:

Undrained elastic modulus at 50 % peak deviation stress (E50) can be correlated with cu value

As for the effective internal friction angle ( ) for sandy soils can be estimated from the modified equation(Kulhawy and Mayne, 1990):

Some carbonates due to shell of micro/macro organisms are observed throughout the depth of soils upto 35% CaCO3 at (mean value 25%) Project site. These carbonates were believed in increase "liquefactionresistance" of sandy soils during seismic loading owing to their roughness structure and reduce inabrasion.

(σv' = effective vertical pressure; γ'=submerged unit weight; z = depth from sea bottom surface)

(qc= measured cone tip resistance in MPa; z = depth from sea bottom surface in meters)

15

PREDICTED AND MEASURED EFFECTIVE INTERNAL FRICTION ANGLE

Note: Robertson (2009) was used for predicted values. Xm = mean value, Xk(1) = characteristicvalue based on student value method, , Xk(2) = characteristic value based on Schneider's method. Source: Yapı Merkezi R&D Department, 2010©

16

BOREHOLE BH1-5


17

SOME ILLUSTRATIVE EXAMPLES OF BOREHOLES

Source: Yapı Merkezi Design and R&D Departments (2010)

BHJ-5 (ASIA SIDE TRANSITION ZONE)BHJ-1 (EUROPE SIDE)0 m

10 m

20 m

30 m

40 m

50 m

60 m

0 m

10 m

20 m

30 m

40 m

50 m

60 m

Sand

Clayey Silty Sand

Mudstone

Sandstone

Mudstone

Diabase

Diabase

Mudstone

Sandstone

Mudstone

0 m

10 m

20 m

30 m

40 m

50 m

60 m

70 m

80 m

90 m

100 m

110 m

Clayey Silty SandSandy Clay Silt

Clayey Silty Sand

Sandy Clay Silt

Sandy Clay Silt

Sand

0 m

10 m

20 m

30 m

40 m

50 m

Clayey Silty Sand

60 m

70 m

Sandy Clay SiltSandSandy Clay Silt

Sand

SandstoneMudstoneSandstone

Mudstone

Sandstone

0 m

10 m

20 m

30 m

40 m

50 m

60 m

70 m

80 m

90 m

0 m

10 m

20 m

30 m

40 m

50 m

60 m

70 m

Sand

Clayey Silty Sand

GravelSandMudstone

Sandstone

BHJ-1 BH1-4 BHJ-5

BH1-4

Source: Bakır, Aydın (2015)

18

Source: YMSK Joint Venture (2015)

EXISTENCE OF DYKE ZONES

In Trakya Formation, Sandstone/Mudstone layers cut through dykes (andesite and diabase).

Such a geological setting creates a different rock mass medium with variable stiffness.

Andesite/Diabase dykes have uniaxial compressive strengths more than 200 MPa.

Cherchar Abrasive Index (CAI) is an indication of cutter disc/tools wear rate and in the case

of dykes, this index increases up to 4.5 (extremely abrasive).

Pinkk color in geological profile below corresponds to dyke zones faced during excavation.

Parameter Asia Side Trakya Formation

Europe Side Trakya Formation Overall Trakya Formation

Number of Dyke Zone 6 23 29

Total Dyke Length (m) 28 397 425

Average Dyke Length (m) 5 17 15

Average Dyke Frequency (m) 113 83 90Source: YMSK Joint Venture (2015)Note: Longest dyke's length is 120.0 m.

19

FACE SUPPORT PRESSURE

"Slurry Pressure: Under the expected conditions, up to 10 bar high slurry pressures

will be necessary for operation in soft ground. This figure is higher than the highest

slurry pressures applied ever worldwide (7 bar) and means "unexplored terrority"

with respect to TBM design and TBM operation."

Quoted from "Istanbul Strait Road Crossing - Expert Panel Opinions on TBM

Type and Operation Report", page 1, 7 September 2009.

by

Prof. Dr. George ANAGNOSTOU

Prof. Dr. Nuh BILGIN

Prof. Dr. Levent OZDEMIR

Prof. Dr. Markus THEWES

20

ESTIMATION OF FACE SUPPORT PRESSURE

0 m

10 m

20 m

30 m

40 m

50 m

60 m

70 m

80 m

90 m

100 m

110 m

0 m

10 m

20 m

30 m

40 m

50 m

Sand

Clayey Silty Sand

Mudstone

Sandy Clay-Silt

Marmara Sea

Face support pressure -at tunnel axis- based on soil/rockmechanic principles:

Horizontal earth pressureHydrostatic water pressure

Expected maximum effective vertical load on shield-neglecting arching effect-:

Mean value of lateral earth coefficient at rest and active state

= Effective internal friction of soil/weak rockmass, 30o -on conservative side-

Face support pressure -at tunnel axis-

TBM was designed on face support pressure of 12 bar.

(Tunnel diameter, D = 13.7 m; submerged unit weight of geomaterial, γ'=0.9t/m3)

(water depth, Hw=62 m; overburden thickness, H=26 m; unit weight of water, γw=1t/m3)

21

DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR

HPERBARIC OPERATIONS IN SUBSEA TUNNELRelationship between face support pressure and cohesion of geomaterial for subsea tunnelconditions for given critical geometric and working conditions, the following relationshipshown in figure can be set up:

Undrained cohesion value of weak, heavily jointed,weathered geomaterial can be estimated from thefollowing semi-empirical equation:

For the rock mass under consideration, internalfriction angle (φ = 15o – 30o), the arithmetic mean

value of can be assumed to be about 0.67,then the above equation is approximated as:

Uniaxial comp. strength of rock mass, = 2.5 MPa

Rock Quality Designation, = 0%

Joint Condition, = 5

Face

Supp

ortP

ress

ure,

Pf

Undrainedcohesion of Geomaterial, c

entirely crushedrock mass

Pf = 3.5 bar withcompressed air

Hyp

erba

ricO

pera

tion

when groundimprovementis applied

If c < com; cohesionvalue correspondingto no face pressurei.e open mode

com

closed mode

Hw

Ho

D Pf

Tunnel

σcm

22

DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR

HPERBARIC OPERATIONS IN SUBSEA TUNNEL

Then, for given conditions, the cohesion value can be calculated as:

Under extreme condition, say, entirely crushed rock mass due to intense tectonic events:

To sum up:

TBM will work in close mode for the stability of excavation face.

To eliminate hyperbaric operations, the long standstill for repair/maintenance of TBM isneeded "safe heavens" by means of ground improvements (deep mix method from sea watersurface, chemical/cementitious injections from inside of TBM, excavation of small diameter of pilottunnel from land side, freezing, jet grouting, etc.) can be applied.

No example Project for ground improvement is present under very high pressure such as11 bar -unmanagable pressure-

Hyperbaric diving is a preferable solution. Hence, the hyperbaric operations with mixedgas for short term standstills (inspection) and saturation for long term standstills(unplanned/planned maintenance + repair works) were adopted in the Project.


23

TUNNEL AND TBM

TU

NN

EL

TBM Tunnel LengthTBM Tunnel Grade

3,340 m± 5%

TB

M -

GE

NE

RA

L Maximum Face PressureTBM DiameterLength of the TBM Weight of the TBMInstalled Total PowerNominal TorqueThrust Force

12 bar13.7 m120.0 m~3,300 t10,330 kW23,289 kNm247,300 kN

TB

M–

SP

EC

IAL

E

QU

IPM

EN

T

Φ2000mm Man LockΦ1600mm Center LockMaterial LockShuttle (3200 x 1600 x 1600 mm)

2 units2 units3 units1 unit

CU

TT

ING

TO

OL

S

Number of Total Disc Cutters Diameter of Disc CuttersSpacing (gauge / center disc cutters)

Atmospheric Changeable Cutting KniveHyperbaric Changeable Cutting Knive

35 (double)

19 inch100mm/120mm48144

SE

GM

EN

TS

Outer Ring DiameterInner Ring DiameterRing ArrangementSegment LengthSegment ThicknessWeight of a Complete Ring

13.2 m12.0 m8+1 keystone2000 mm600 mm127 t Mixix-x-Shieldd Slurryy Tunnelel Boringg Machine

24

TUNNEL SEGMENTS

Producer Yapı Merkezi Prefabrication

Ring Diameter * Outer (13.2 m)* Inner (12.0 m)

Segment Length 2 m

Segment Thickness 0.6 m

Ring Arrangement * Universal* 8 + 1 keystone

Segment Weight ~ 15 t

Ring Weight ~ 127 t

ERQ 28-days Comp. Strength Limit 50 MPa

Average 28-days Comp. Strength of Production 72 MPa

ERQ Rapid ChloridePermeability Limit 1000 Coulomb

Average Rapid ChloridePermeability 280 Coulomb

ERQ Service Life Limit 100 years

Estimated Minimum Service Life 127 years

15.048 piece 600-mm-thick precast segments (1.672 rings)

27.100 t cement

200 t hyperplasticizer

4.800 t fly ash

66 ton polypropylene fiber

79.468 m³ concrete

More than 60.000 QA/QC tests Connected by using 30.765 bolts

Only 0.3% of producedsegmenst were found tobe deficient due toexistance of cracks withwidth more than 0.2 mm.

25

COMPARISON OF TBM TUNNEL PROJECTS (FACE PRESSURES AND DIAMETERS)

0 500 1000 1500 2000 2500

TTBM Design

Applied

Lake Mead, USA

Eurasia, TURKEY

Hallandsas, SWEDEN

Shanghai Chongming, CHINA

Nanjing, CHINA

Weser, GERMANY

St Petersburg, RUSSIA

Tokyo Wan, JAPAN

Hamburg – Elbe, GERMANY

Westerschelde, NEDERLAND

=7.2 m

=13.7 m=10.6 m

=15.4 m

=14.9 m

=11.7 m

=7.4 m

=14.1 m

=14.2 m

=11.3 m

DIAMETER2 X PRESSURE (m2.bar)

Eurasia Tunnel TBM ( = 13.7 m) is leading the investigated group of 10 projects when the

“Diameter2 x Pressure” parameter is considered. Source: Untreated data from Anagnostou(2014) and Holzhauser et al. (2006)

HIGHEST DESIGN PRESSURE Pf-design = 17.0 bar

Pf-design = 12.0 bar

26

ADVANCE RATES BASED ON VARIOUS UNITS

As expected, the coefficient of variation value i.e. magnitude of variability in advance ratewas obtained highest in daily advance rate.

The ratio of (maximum value / average value) was varying between 1.5 and 2.6.

Statistical Parameters Daily Weekly Monthly

Time 476 days 68 weeks 16 months

Maximum 18.0 m/day 86.7 m/week 316.0 m/month

Minimum 0 0 90.0 m/month

Average 7.0 m/day 49.0 m/week 208.3 m/month

Standard Deviation 5.1 m/day 26.6 m/day 64.4 m/day

Coefficient of variation 72 % 54 % 31 %

Source: Yapı Merkezi R&D Department, 2015©

27

DAILY ADVANCE RATE & SHIELD DIAMETERD

aily

Adv

ance

Rat

e, m

/day

Tunnel Diameter, D, m0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

0

2

4

6

8

10

12

14

16

18

20

22

24

26

Lower Lİmit

Upper Limit

Project Name General Geology/ Formation

Grauholz (1) Sand, Gravel, Debris

Mülheim (1) Sandstone, Claystone

Strasbourg (1) Gravel, Sand

Taipei (1) Clay

Cairo (1) Sand

Duisburg (1) Limestone, Gravel, Clay

Heinenoord (1) Sand, Clay

Zurich Glatt (1) Debris,unconsolidated materials

Sydney (1) Clay, sand, sandstone

Buenos Aires (1) Sand, Gravel, Clay

Hamburg (1) Gravel, marn, rock block

Berlin (1) Sand, clay

İzmir (1) Sand, clay

Madrid (1) Clayey Soil, sand, clay

Düsseldorf (1) Fine sand, sandy gravel, stones

Singapore (1) Sediment, clay

Botlek (1) Clay, coarse sand, gravel

SMART(2) Carstic limestone, sediment

Lefortovo(3) Sand carrying water, silt, laminated limestone alternatedkil

Channel Tüneli(4)

Limestone, marn, weak sandstone

(1) Values were taken from TKJV TBM Expert Report, 2009.(2) Carter & Burgess, Inc., 2007.(3) Herrenknecht, Bäppler, 2006.(4) Harris, vd., 1996.

Upper U ppep rppUpperLimitL mitiLimit

D=1

3.7m

Formation / Section Ave.

Trakya Formation (4 days of Holiday excluded)

6.8 m/day

Transition Zones 8.6 m/day

Marine Sediments (4 daysHoliday & 13 days seismic joints)

9.2 m/day

Overall 7.0 m/day

Overall without MandatoryStandstills (8 days Holiday & 13 days seismic joints)

7.3 m/day

Overall without MajorStandstills (112 days of majorstandstills that are more 1 day)

9.1 m/day

r r LimitL miti t

tion Avee. .

days of 6.8m/day

8.6 m/day

daysic joints)s

9.2m/day

7.0 m/day


28

COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS

Project Name EURASIA SHANGAI - I SHANGAI - II

Project Country Turkey China China

GeologyTrakya & Marine

SedimentsSand & Clay Sand and Clay

TBM Tunnel Length (m) 3340 7476 7472

TBM Tunnel Type Highway Highway Highway

TBM Manufacturer Herrenknecht Herrenknecht Herrenknecht

TBM Type Mix-Shield Mix-Shield Mix-Shield

TBM Diameter (m) 13.7 15.4 15.4

TBM Cutterhead Power (kW) 4900 3750 3750

Cutterhead Power per Unit Area (kW/m2)

33.3 20.2 20.2

Wee

kly

Adv

ance

Rat

e Number of Weeks 68 88 73

Maximum (m) 86.7 (@ marine sediments) 144 140

Minimum (m) 0 0 0

Average (m) 49.0 85.0 88.8

Standard Deviation (m) 26.6 36.3 35.3

Coefficient of Variation (%) 54 43 40

29

At first glance, weekly advance rate in Shangai-I and Shangai-II TBM Projects are markedly

higher than Eurasia Tunnel.

Taking consideration into magnitude of "face support pressure x cross section area of

cutterhead", one obtains the following figures:

Eurasia Tunnel….…………..120 t/m2 x (π/4) x (13.7 m)2 = 17680 t

Shangai Tunnel…………….. 60 t/m2 x (π/4) x (15.4 m)2 = 11170 t

The horizontal force resulting from face support pressure at Eurasia Tunnel is about 1.58

times higher than Shangai Tunnels.

There is no section with highly fractured rock mass in route of Shangai tunnels. Hence, it is

expected to experience higher penetration rate leading to ultimately higher weekly advance

rate. As for the borability of TBM in Eurasia Tunnel Project, ground is extremely variable

from one point to other point due to different stiffness and jointing degree.

COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS

30

FACE SUPPORT PRESSURE & TOTAL THRUST FORCE

Excavationn Direction

239000 kN(97 % of design capacity)

10.8 bar(90 % of design capacity)

1st Hyperbaric Maintenancefor "Suction Grid Repair"

at ction Grid Reat 10.8 bar

2nd Hyperbaric Maintenancefor "Cutterhead Inspection"

at erhead Inspeat 10.3 bar

3rd Hyperbaric Maintenancefor "Suction Grid Repair"

at tion Grid Reat 9.8 bar

4th Hyperbaric Maintenancefor "Boulder Crusher Repair"

at er Crusher

at 8.5 bar

Abo

vee4.

5 ba

r,

r,sa

tura

tionn

divi

nggis

ssre

quir

edA

bov

for

vee.5

bar

4r,

sabo

voroor

man

inte

nanc

eatur

a cececece/

atio

nra

tur

eee///re

pair

ivin

gd

gis

seqre

onnd

irirrop

erat

ions

Source: Arioglu et al. 2016©

31

DETAILED OVERVIEW OF STANDSTILLS

No Ring(distance)

CompletedTunnel (%)

Face SupportPressure (bar)

Duration(days) Description of Standstill

1 126(252 m)

7.5 4.2 20Cutterhead repair by compressed air diving (Cutterhead damaged due to failure of disc cutter sensors thereby failure of gauge cutters. Some buckets replaced, composite plates and pins welded)

2 195(390 m)

11.7 5.2 9 Disc cutter replacement under athmospheric pressure

3 270(540 m)

16.2 6.0 9 Disc cutter replacement under athmospheric pressure

4 430(860 m)

25.7 8.2 6 Asian side seismic joint installation

5 568(1136 m)

34.0 9.0 4 Religious holiday

6 587(1174 m)

35.1 9.7 6Cutting tool and brush replacement under athmosphericpressure

7 690(1380 m)

41.3 10.1 7 European side seismic joint installation

8 875(1750 m)

52.4 10.8 15 Suction grid repair by saturation diving

9 933(1866 m)

55.9 10.5 8 Cutterhead inspection by saturation diving (6 cm x 75 cm x 200 cm metal pieces were taken out from jaw crusher area)

10 1003(2006 m)

60.1 10.1 5 Suction grid repair by saturation diving (Middle section of the old suction grid was removed and the new one was installed)

11 1146(2292 m)

68.6 8.9 19 Boulder crusher repair by saturation diving

12 1499(2998 m)

89.8 4.2 4 Religious holiday

Total Standstills 112 Note that 8 days holiday and 13 days seismic joint installations weremandatory.


32

SUMMARY OF HYPERBARIC WORKS UNDER APPROXIMATELY 11 BAR PRESSURE

Starting from excavation of Ring-870 (1740 m), someblockage issues in suction line was observed and inconsecutive 5 days daily advance rate is approximately1.7 m/day due to same issue (5 days period averagecutterhead speed, penetration, total thrust force and torquevalues are 1.8 rpm, 6.7 mm/revolution, 162 MN and 6.2 MNm,respectively). Operational parameters indicate anomally.

Blocked pipes were investigated and larger diameterrock units were identified. It was thought that reason isthe damaged / deteriorated grid behind the stone crusher.The grid became non-functional. For this reason,hyperbaric works were carried out at Ring-875 (1750 m).

The summary of condition at Ring-875 is as follows:

Excavated Geological Unit: Trakya Formation (RockQuality Designation, RQD < 25 % and very weak highly jointedrock mass conditions)

Face Pressure: 10.8 bar (90 % of the TBM design pressure)

Depth of TBM Tunnel -bottom of tunnel from sealevel-: ~103.0 m (note that the deepest point was 106.4 m)

Type of Hyperbaric Works: Saturation

Total Standstill Duration of TBM for HyperbaricMaintenance: 14 days

Stuckedd SSStones Stuckedd Stone (~24 cm)

New w Grid

Technical Drawing of

Grid

Damagedd Grid

DiversDiversSource: Yapı Merkezi R&D Department, 2015©

33

CUTTERHEAD TORQUE

Average cutterhead torque values in Asia side Trakya formation, marine sediments and Europe sideTrakya formation are 10.0 MNm, 4.5 MNm and 6.0 MNm, respectively.

Torque values were representing a high variation (38 %) in Asia side Trakya formation due to varyingformation characteristics. When the marine sediment excavation started, torque values were decreasedand the variations were decreased to (22 %).

Euro

pean

Side

Sei

smic

Join

t

Asi

anSi

de S

eism

icJo

int

Europe – Trakya FormationMarine Sediments and Transition ZonesAsia – Trakya Formation


34

CUTTERHEAD TORQUE AND SPEED

Prod

ucer

Lim

it =

3.2

rpm

Limit Torque

Nominal Torque

Cut

terh

ead

Torq

ue(M

Nm

)

Cutterhead Speed (revolution per minute)Source: Yapı Merkezi R&D Department, 2015©

Trakya Formation

Marine Sediments

35

SPECIFIC ENERGY CONSUMPTION

The lowest cutterhead electricity consumption was observed during excavation of marine sediments withan average specific energy value of 3.1 kWh/m3. Spent average specific energy in Asia and Europe sideTrakya formation were 15.9 kWh/m3 and 14.3 kWh/m3, respectively.

At some rings, it was observed that the specific energies were jumped due to existance of dyke zones.

Euro

pean

Side

Sei

smic

Join

t

Asi

anSi

de S

eism

icJo

int

Europe – Trakya FormationMarine Sediments and Transition ZonesAsia – Trakya Formation


36

RELATIONSHIP BETWEEN SPECIFIC ENERGY AND PENETRATION

Curve approximated by Authors based on thedata given in Barla (2000).( 11.8m; through Dolomite, Limestone and Argillite Formations)

Curve generated from the Eurasia Tunnel data

37

RINGBUILD DURATION

Source: Limits by Maidl and Comulada (2011), Eurasia

data by Yapı Merkezi R&D Department, 2015©

EurasiaTunnel(φ13.7 m)

Learning Period

Eurasia Tunnel TBMMaximum segment weight is 15 t andcomplete weight of 8+1 ring is 127 t.Segment erector's rated load is 16 t.

38

TBM EXCAVATION PARAMETERS

Excavation ParametersAsia

Trakya Formation(Rings: 0 - 282)

AsiaTransition Zone(Rings: 283 - 338)

Marine Sediments

(Rings: 339 - 714)

EuropeTransition Zone(Rings: 715 - 770)

EuropeTrakya Formation(Rings: 771 - 1670)

Overall(Rings: 0 - 1670)

Excavation Dates 5/5/14 - 6/8/14 7/8/14 - 15/8/14 16/8/14 - 22/11/14 23/11/14 - 9/12/14 10/12/14-23/8/15 5/5/14-23/8/14

Calendar Days 94 9 99 17 257 476

Major Stop Days 38 0 23 0 51 112

Section Length (m) 564 112 752 112 1800 3340

Average Advance Speed (mm/minute) 20.2 28.6 24.4 14.9 13.9 17.8

Average Penetration (mm/revolution) 9.2 10.0 18.4 7.0 5.9 9.4

Average Cutterhead Speed (rev. per minute) 2.2 2.9 1.5 2.2 2.4 2.2

Average Torque (MNm) 9.8 7.6 3.7 7.0 6.0 6.2

Minimum Total Thrust Force (kN) 57,841 94,406 106,920 154,476 21,679 21,679

Maximum Total Thrust Force (kN) 113,240 122,683 238,935 210,517 199,412 238,935

Min. Pressure -TOP- (bar) 0 5,3 6,2 9,4 0 0

Max. Pressure -TOP- (bar) 5.4 6.3 9.6 9.7 9.8 9.8

Specific Energy (kWh/m3) 15.9 10.6 3.4 17.1 14.3 12.1

Average Advance (minutes/ring) (*) 105 71 84 145 146 123

Average Ringbuild (minutes/ring) (**) 62 45 53 51 44 49

Average Downtime (minutes/ring) (***) 105 100 97 129 101 102

(*) Higher advance durations (tadvance > 300 minutes/ring) are excluded.(**) Higher ringbuild durations (tringbuild > 120 minutes/ring) are excluded.(***) Major stop durations (tdowntime > 1,000 minutes/ring) are excluded. Source: Yapı Merkezi R&D Department, 2015©

39

REPLACED DISC CUTTERS, SCRAPERS AND BRUSHES

ToolAsia Side

Trakya Formation(0 – 564 m)

Transition Zones andMarine Sediments

(565 m - 1540)

Europe SideTrakya Formation(1541 m – 3340 m)

TotalNumber

Disc Cutter 54 69 325 448

Scraper 16 17 52 85

Brush 0 475 0 475

DiscCutterType

Number on Cutterhead

Average ExcavatedLinear TunnelDistance (m)

Average TrackedLength (km)

AverageExcavated

Volume (m3)

Center 6 1534 834 1445

Face 23 284 984 1126

Gauge 6 97 697 703

Replacement number of tools by considering formation in Eurasia Tunnel.

Some excavation parameters by considering disc cutter type in Eurasia Tunnel.



40

Geometric Restrictions:

Tunnel diameter (two-deck road tunnel)

Overburden (minimum 2 times diameter)

Gradients (±5%)

Highly Active Seismicity:

Slip rate of about 20-24 mm/year on fault system based on the GPS measurements

Distance to North Anatolian Fault Zone is 16 km

The probability of a Mw ≥ 7.0 earthquake is 35 – 70 % in the next 30 years

First application of seismic joint for subsea tunnel in worldwide

Extremely Variable Geology:

Subjected to twice "orogenic events" in history

Trakya formation with volcanic dyke intrusions (5 – 250 MPa)

Transition zones

Faulted and weakness zones

Marine sediments

MAJOR CHALLENGES - I

41

Hyperbaric and Operational Conditions:Risky project since face support pressures were above 4.5 bar for 79% of the alignment with respect ofsaturation diving by nitrox/trimix gas mixture

Saturation diving with nitrox/trimix gas mixture where face support pressures are above 4.5 bar

First application of hyperbaric operation under 11 bar in worldwide TBM projects.

4 times hyperbaric maintenance/repairs

Aggressive Medium:

Volcanic dykes of andesite and diabase.

28 dyke intrusions

Total length of 413 m (12 % of tunnel)

Frequency of about 90 m

Thicknesses between 1 m and 120 m

UCS more than 200 MPa

CAI values are reaching up to 4.5 (“abrasive” and “very abrasive” classes)

High Capacity Demands:

Face support pressure of 10.8 bar (90% of capacity)

Thrust force of 239 MN (97% of installed capacity)

Torque of 20 MNm (86% of nominal capacity)

Separation plant usage for 18.0 m/day (90% of capacity which is 2800 m3/day)

MAJOR CHALLENGES - II

42

CONCLUSION

Responses to ChallengesPreliminary studies (literature/desk studies and detailed site/laboratory investigations)

Latest Mixshield TBM technology (advanced monitoring systems, atmospherically changeable cutting tools, special pressure equipment)

Seismic Joints (innovated, designed, localized, tested, implemented)

Continuous monitoring and utilization of gained knowledge (excavation parameters and downtime root causes) on upcoming excavation phases

Best experts for all aspects of the project

Utilizing and developing technologyEffective learning (cutting tool replacement duration, ringbuild duration, interaction between rockmass/soil andTBM, practical solutions at site)

Experienced TBM crew (average 2.8 TBM projects / personnel and average 15.0 km TBM tunnel / personnel)

Collaborative and succesful Project Management and Yapı Merkezi Prefabrication Factory

Breakthrough: 22/08/2016 - 17:00

Average Daily Advance Rate: 7.0 m/day

Utilization Ratio: 31%

43

Owner : Ministry of Transportation

General Directorate of Infrastructure Investments (AYGM)

Investor/Contractor : Avrasya Tüneli İşletme, İnşaat ve Yatırım A.Ş. (ATAŞ)

Yapı Merkezi and SK EC Joint Venture (YMSKJV)

Yapı Merkezi : Board Members

Host : Turkish Tunnelling Society

ACKNOWLEDGEMENT

“... the Project will encourage the tunnelingworld to attempt deeper, farther and larger ...”

Dr. Ersin ARIOĞLU (2015)Founder of Yapı Merkezi

44

Wee wouldd likee too thankk youWee wfor

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youyankknn ourr youry r nteresin t

presentationn ot ninn

nn...

Source: Arıoğlu, Ersin (2016)